Method for weaving contoured thread connected dual wall inflatable fabric



Jan. 11, 1966 E. BILSKY 3,228,425

METHOD FOR WEAVING CONTOURED THREAD CONNECTED DUAL WALL INFLATABLEFABRIC Filed Dec. 4, 1963 INVENTOR.

E A /?L B/LSK Y ATTORNEY United States Patent 3,228,426 METHOD FORWEAVING CONTOURED THREAD CONNECTED DUAL WALL INFLATABLE FABRIC EarlBilsky, Lawrence, Mass, assignor to Goodyear Aerospace Corporation,Akron, (lhio, a corporation of Delaware Filed Dec. 4, 1963, Ser. No.328,020 Claims. (Cl. 139-20) This invention relates to a method forweaving contoured thread-connected dual wall inflatable fabric, and moreparticularly to a method for weaving double spaced fabrics with extendeddrop yarns therebetween so that when the fabrics are moved apart afterweaving, a desired contour is attained between the fabrics because ofthe extended lengths of the drop yarns.

Thread-connected dual wall inflatable fabric is manufactured and sold byGoodyear Aerospace Corporation of Akron, Ohio, under the trademarkAirmat registered in the US. Patent Office.

Thread-connected dual wall inflatable fabric, hereinafter for simplicitycalled inflatable fabric, has been made with the threads, sometimescalled drop yarns, of fine steel wire or of light but strong natural orsynthetic fibers or filaments.

Inflatable fabric of this type when inflated provides a high strengthper unit weight ratio. It consists of an upper and lower woven fabricconnected by drop yarns of equal length for flat inflatable fabric orvarying lengths for contoured inflatable fabric. At present, however, itis not possible to accurately and/or automatically vary the length ofthe drop yarns to make contoured inflatable fabric. Thus, using theplush or carpet looms of the art only flat inflatable fabric ofapproximately three inches thickness is possible, however, flatinflatable fabric can be made up to approximately six inches inthickness by including false picks to extend the drop yarns which picksare later removed.

Until the technique for weaving contoured inflatable fabric, asdisclosed hereinafter, was developed, it was necessary to cut fabricsinto strips and gores which were sewn together to produce shapes such ascones, spheres and air foils. This procedure was not only costly andtime consuming, but also precluded, to a great extent any attempt toproduce such shapes with any degree of similarity.

Heretofore, the art of double fabric weaving on plush or carpet loomshas been well known. In these looms a top and bottom fabric are wovensimultaneously in substantially parallel spaced relationship with aplurality of drop yarns extending from fabric to fabric. These dropyarns are split substantially in the middle to separate the two fabricsand create the nap or plush surface of a carpet. Further, these plushlooms have been used to make inflatable fabric having uniform crosssectional areas. However, the maximum spacing between fabrics generallycannot be more than six inches which limits the maximum depth of thefabric drop yarn combination to six inches. Further, it is not possibleto attain either longitudinal or transversed tapers or curves to thefabric with the looms of the present art.

Therefore, it is the general object of the invention to avoid andovercome the foregoing and other difliculties of prior art practices bythe provisions of a method to weave contoured inflatable fabric on adouble fabric plush loom by extending the drop yarns from each fabricthe desired length during the weaving.

A further object of the invention is to provide a method for weavingcontoured inflatable fabric on a double fabric plush loom whereby thedrop yarns are extended during the weaving thereof, and which extensionis highly accurate and controllable to insure a precision inflatablefabric with a high strength to weight ratio.

Another object of the invention is to provide a method highly accurate,extremely effective, and which is low in for weaving contouredinflatable fabric which is simple, cost.

The aforesaid objects of the invention and other objects which willbecome apparent as the description proceeds are achieved by providing amethod to weave contoured inflatable fabric which comprises the steps ofweaving a top and bottom fabric of wire yarn in substantially par allelspaced relationship, maintaining the woven fabrics in substantially thesame spaced relationship while moving them away from the weaving edge,weaving a plurality of drop yarns longitudinally into each fabric,crossing the drop yarns over from one fabric to the other, extending thecrossed over drop yarns from the top fabric a predetermined lengthbetween the fabrics while spacing them from the lower fabric, andextending the crossed over drop yarns from the bottom fabric apre-determined length between the fabrics while spacing them from thetop fabric.

For a better understanding of the invention reference should be had tothe accompanying drawings, wherein:

FIGURE 1 is a schematic line diagram of one embodiment of the method ofthe invention;

FIGURE 2 is a schematic line diagram of a slightly altered version ofthe embodiment of FIGURE 1, and

FIGURE 3 is a schematic line diagram of another embodiment of the methodof the invention which extends the drop yarns outside the fabrics.

With reference to FIGURE 1 of the drawings, the numeral 1 indicates atop fabric and numeral 2 represents a bottom fabric. The top fabric 1 iswoven from a plurality of warp yarns 3 and 4 which define a top shed 5.Likewise the bottom fabric 2 is woven from a plurality of warp yarns 6and 7 which define a bottom shed 8. Weft yarns 9 and 10 are received inthe sheds 5 and 8 and are beaten up into weaving edges 11 and 12 usuallyby means of a reed mechanism (not shown). The woven fabrics 1 and 2 aretaken away from the weaving edges in substantially straight, parallelspaced relationship to allow the extention method described hereinafter.

A plurality of drop yarns 13 and 14 are woven longitudinally into thefabrics 1 and 2 in substantially parallel relationship to the warpyarns, with the drop yarns 13 and 14 being crossed over from one fabricto the other between about every two and about every twenty picks of theweft yarns 9 and 10. It should be understood that substantiallyconventional dobby or jacquard mechanism will be used to control thepositioning of all the yarns during the weaving. FIGURE 1 illustratesthe drop yarns 13 and 14 having been crossed over to form a cross overpoint 15. However, before the drop yarns 13 and 14 are rewoven back intotheir respective fabrics 1 and 2, they are extended, as will bedescribed hereinafter. Thus, it is seen that the fabrics 1 and 2comprise longitudinally running warp yarns, transversely running weftyarns, and longitudinally running drop yarns crossing over betweenfabrics. The invention contemplates that the yarns shall be metallichaving diameters between about .0015 and about .005 inch. However, theyarns may be nylon, rayon, or natural or synthetic materials which willgive the desired strength to weight ratios.

The important feature of the invention is to provide extension of thedrop yarns 13 and 14 to pro-determined lengths before they are rewoveninto the fabrics 1 and 2 so that when the fabrics 1 and 2 are made airimpervious and the sides enclosed the structure may be inflated allowingthe drop yarns to extend and provide desired contours between thefabrics 1 and 2. Therefore, in order to achieve the extension of thedrop yarns 13 and 14, a stationary central rod 16 and side rods 17 and18 adjacent the inside of the fabrics 1 and 2 may be provided.

The stationary rod 16 is positioned so that it is between the cross overpoint and the weaving edges 11 and 12. The movable rods 17 and 18 arepositioned inside and adjacent the fabrics 1 and 2 and behind therespective cross over yarns 13 and 14. Therefore, when the movable rods17 and 18 are moved forwardly substantially parallel to and between thefabrics 1 and 2 to a position indicated by dotted lines 19 and 20, thedrop yarns 13 and 14 are extended to the dotted line positions 21 and22. Thus, it is seen that the drop yarn-s 13 and 14 are extendedindividually to a length accurately determined by a distance X,indicated by numeral 23, which defines the distance from the stationarybar 16 to the extended positions of the movable bars 17 and 18. Also, itshould be noted that each extended drop yarn is spaced by the stationarybar 16 from the other fabric and the other drop yarns to preventtangling. Of course, the movable bars 17 and 18 could be movedpre-determined variable distances to provide variable extension of thedrop yarns to achieve the desired contour between the fabrics 1 and 2.

FIGURE 2 illustrates a modified version of the method utilized in FIGURE1 where everything is essentially the same except that the stationarybar 16 is moved up so that it is substantially in line with the weavingedges 11 and 12. In this manner the drop yarns 13 and 14 may be crossedover and beaten up to the weaving edges 11 and 12 so that they areessentially perpendicular thereto as indicated by the single line 24.After the drop yarns are beaten up into position the movable bars 17 and18 may then move between the fabric layers 1 and 2 to the positionsindicated by dotted lines 1901 and 20a which extends the drop yarns 13and 14 to the positions indicated by the dotted lines 21a and 2211. Inthis instance the extension of the drop yarns 13 and 14 is even moreaccurately controlled because the distance of extension X, indicated bynumeral 25 is exactly equal on both sides of the movable bars 17 and 18,and further since both bars 17 and 18 are behind the drop yarnsindicated by the straight line 24 both the drop yarns 13 and 14 areextended by each movable bar so that the total distance moved is equalto substantially four X. Thus, it is seen that simply by controlling thepositioning of the rods 17 and 18 either behind only one drop yarn asshown in FIGURE 1, or behind both drop yarns, as shown in FIGURE 2, onecan quickly and easily control the amount of extension to the dropyarns.

In the embodiments of the invention shown in FIG- URES 1 and 2 it iscontemplated that the drop yarns will be woven back into theirrespective fabrics after extension to hold. them in position. Theinvention further contemplates that the extended drop yarns may be heldin the extended position until the completion of weaving to preventtangling thereof.

FIGURE 3 represents a method of extending the drop yarns outside thefabric layers. In this case a pair of substantially parallel spacedfabric layers and 31 are made up from warp yarns 32, 33, 34, and 35. Thewarp yarns 32 and 33 describe a shed 36 while the warp yarns 34 and 35describe a shed 37. Weft yarns 38 and 39 are received in the sheds 36and 37, respecitvely. A plurality of drop yarns 40 and 41 are crossedover from the weaving edges 42 and 43 to provide a cross over point 44.In order to provide the extension of the drop yarns 40 and 41 a pair ofmovable rods 45 and 46 are provided. The rods 45 and 46 are placedbehind the drop yarns 40 and 41 and outside the outer warp yarns 32 and35. In this position the movable rods 45 and 46 can move forwardlytowards the fabrics 30 and 31 in substantially parallel relation on theoutside thereof to the position indicated by the dotted lines 47 and 48which provides an extension of the drop yarns 40 and 41 to the positionindicated by the dotted lines 49 and 50. This extension will move thedrop yarns 40 and 41 to a position perpendicular to the weaving edges 42and 43 which is indicated by the dotted line 51. The extension in thiscase is indicated by the disthat each individual drop yarn is extended adistance 2X by the movable rods 45 and 46 with the extension takingplace outside the fabrics 30 and 31. With this method of extension thedrop yarns extension will remain outside the woven fabrics 30 and 31while the drop yarns are rewoven back into their respective fabrics andthen pulled down to their extended length when the fabric layers 30 and31 are made air impervious and covered and inflated to provide thedesired contours.

It is contemplated that the drop yarn cross overs will be made betweenabout every two and about every twenty picks of the weft yarns with thedrop yarns extended before they are rewoven back into the fabrics. Amethod of internal extension of each individual drop yarn, and a methodof internal extension of both drop yarns together, and a method ofexternal extension of the individual drop yarns have been illustratedand described in detail.

However, it is to be understood that while in accordance with the patentstatutes only one embodiment of the invention has been illustrated anddescribed in detail, it is to be particularly understood that theinvention is not limited thereto to thereby, but that the inventivescope is defined in the appended claims.

What is claimed is: 1. A method to weave deep piled contoured inflatablefabric which comprises the steps of weaving a top and bottom fabric ofwire yarn having a diameter of between about .0015 and about .005 inch,said fabrics composed of longitudinally running warp yarns andtransversely running weft yarns, said fabrics being in substantiallyparallel spaced relationship, taking the fabrics away from the weavingedge in substantially straight and parallel spaced relationship,

weaving a plurality of drop yarns longitudinally into each fabric insubstantially parallel relationship to the warp yarns,

crossing said drop yarns over from one fabric to the other between aboutevery two and about twenty picks of the weft yarn, positioning anextension bar in front of the crossed over drop yarns from the topfabric, moving said bar into the spaced opening between fabrics therebyextending the crossed over drop yarns from the top fabric apredetermined length inbetween the fabrics while spacing them from thelower fabric,

positioning an extension bar in front of the crossed over drop yarnsfrom the bottom fabric, moving said bar into the spaced opening betweenfabrics thereby extending the crossed over drop yarns from the bottomfabric a pre-determined length inbetween the fabrics while spacing themfrom the top fabric, and

weaving the crossed over and extended drop yarns into their respectivefabrics.

2. A method to weave deep piled contoured inflatable fabric whichcomprises the steps of weaving a top and bottom fabric of wire yarn,

taking the fabrics away from the weaving edge in spaced relationship fora considerable distance, weaving a plurality of drop yarns into eachfabric, crossing said drop yarns over from one fabric to the other,positioning restraining means behind the crossed over drop yarnsparallel to the weaving edge between the fabrics,

positioning an extension bar in front of the drop yarns from the topfabric and moving it between the top fabric thereby extendingthe crossedover drop yarns from the top fabric a pre-determnied length inbetweenthe fabrics while the restraining means spaces them from the lowerfabric, and

positioning an extension bar in front of the drop yarns from the lowerfabric and moving it between the restraining means and the lower fabricthereby extending the crossed over drop yarns from the bottom fabric apre-determined length inbetween the fabrics While the restraining meansspaces them from the top weaving a plurality of drop yarns into eachfabric,

crossing said drop yarns over from one fabric to the other,

beating the crossed over drop yarns up to the weaving fabric. 5 edge, 3.A method to weave deep piled contoured inflatable positioning anextension bar on the outside of each fabric which comprises the steps offabric substantially parallel to the weaving edge Weaving two fabrics insubstantially parallel spaced thereof in front of the crossed over dropyarns and relationship, said fabrics comprising longitudinally movingthe bars outside the fabrics parallel thereextending warp yarns andtransversely extending 10 to along the fabrics away from the weavingedges weft yarns, thereby extending the crossed over drop yarns intakingthe fabrics away from the weaving edge a subdividually outside thefabrics to pre-determined stantial distance in substantially straightand parallel length, and spaced relationship, weaving the extended dropyarns into their respective weaving a plurality of drop yarnslongitudinally into fabrics.

each fabric in substantially parallel relationship to 5. A method toweave deep piled contoured inflatable the warp yarns, fabric accordingto claim 4 which includes holding each crossing said drop yarns overfrom one fabric to the drop yarn in spaced relation from every otherdrop yarn other, and the fabrics during movement by said extension bars.beating the crossed over drop yarns up to the weaving edges, b h d h dReferences Cited by the Examiner positioning a restraining means e in te crosse over drop yarns substantially between and parallel to theUNITED STATES PATENTS Weaving edges Ofthe fabrics, 1,976,793 10/1934Mangold. positioning extension means in front of the crossed 2,025 21935 Holmes -139 20 over drop yarns and moving said extension means 2045,039 193 h 139 334 into the space between the fabrics on each side of2 317 513 4 1943 Brindle 139 2 the restraining means thereby extendingthe crossed 2 35 45 3 1944 Gamer 39 39 X over drop yarns togetherpre-determined lengths be- 2 37 430 3/ 1953 M m 139 410 tween thefabrics while the restraining means effects 2 57 71 11 1953 Ford 139 410spacing the extended end from the fabrics, and 2 743 510 5 1956 Mammy et1 139-410 X weaving the extended drop yarns into their respective 2 34301 3/1953 N il 139 41 fabrics- 3,00s,213 11/1961 Foster et al. 139-410 X4. A method to weave contoured inflatable fabric 3,043,198 1952Koppelman et 1 139 41 X which comprises the steps of weaving a top andbottom fabric of wire yarn so that FOREIGN PATENTS the fabrics are insubstantially parallel spaced rela 69,100 12/1951 Netherlandstionship,said fabrics composed of longitudinally extending warp yarn andtransversely extending weft 3 moving the fabrics away from the weavingedge a considerable distance in spaced relationship,

DONALD W. PARKER, Primary Examiner.

J. KEE CHI, Assistant Examiner.

1. A METHOD TO WEAVE DEEP PILED CONTOURED INFLATABLE FABRIC WHICHCOMPRISES THE STEPS OF WEAVING A TOP AND BOTTOM FABRIC OF WIRE YARNHAVING A DIAMETER OF BETWEEN ABOUT .0015 AND ABOUT .005 INCH, SAIDFABRICS COMPOSED OF LONGITUDINALLY RUNNING WARP YARNS AND TRANSVERSELYRUNNING WEFT YARNS, SAID FABRICS BEING IN SUBSTANTIALLY PARALLEL SPACEDRELATIONSHIP, TAKING THE FABRICS AWAY FROM THE WEAVING EDGE INSUBSTANTIALLY STRAIGHT AND PARALLEL SPACED RELATIONSHIP, WEAVING APLURALITY OF DROP YARNS LONGITUDINALLY INTO EACH FABRIC IN SUBSTANTIALLYPARALLEL RELATIONSHIP TO THE WARP YARNS, CROSSING SAID DROP YARNS OVERFROM ONE FABRIC TO THE OTHER BETWEEN ABOUT EVERY TWO AND ABOUT TWENTYPICKS OF THE WEFT YARN, POSITIONING AN EXTENSION BAR IN FRONT OF THECROSSED OVER DROP YARNS FROM THE TOP FABRIC, MOVING SAID BAR INTO THESPACED OPENING BETWEEN FABRICS THEREBY EXTENDING THE CROSSED OVER DROPYARNS FROM THE TOP FABRIC A PREDETERMINED LENGTH INBETWEEN THE FABRICSWHILE SPACING THEM FROM THE LOWER FABRIC, POSITIONING AN EXTENSION BARIN FRONT OF THE CROSSED OVER DROP YARNS FROM THE BOTTOM FABRIC, MOVINGSAID BAR INTO THE SPACED OPENING BETWEEN FABRICS THEREBY EXTENDING THECROSSED OVER DROP YARNS FROM THE BOTTOM FABRIC A PRE-DETERMINED LENGTHINBETWEEN THE FABRICS WHILE SPACING THEM FROM THE TOP FABRIC, ANDWEAVING THE CROSSED OVER AND EXTENDED DROP YARNS INTO THEIR RESPECTIVEFABRICS.